Kiel Johnson and Klai Brown has made a Cool 8-bit costume for a Toshiba commercial. Called Gary. They cut the "large pixels" from sheets of high density foam and glued them to "an articulated cardboard suit structure". Kiel said:
"I think I cut around 4000 pixels. Not all used for Gary... we are building two more characters for a video project." He's posted a posted a slew of terrific images from the build and commercial shoot.